Methods and apparatus for thin-walled geometries for additive manufacturing

ABSTRACT

The present disclosure generally relates to methods and apparatuses for additive manufacturing (AM) that utilize a pulsed laser to solidify a liquid photopolymer. The method includes scanning a first portion of the photopolymer with the laser at a first draw speed, wherein the first portion of the photopolymer corresponds to a first portion of the part that has a width less than a threshold width. The method also includes scanning a second portion of the photopolymer with the laser at a second draw speed that is greater than the first draw speed, wherein the second portion of the photopolymer corresponds to a second portion of the part that has a width greater than the threshold width.

INTRODUCTION

The present disclosure generally relates to methods for additivemanufacturing (AM) based on computer aided design (CAD) models.

BACKGROUND

AM processes generally involve the buildup of one or more materials tomake a net or near net shape (NNS) object, in contrast to subtractivemanufacturing methods. Though “additive manufacturing” is an industrystandard term (ASTM F2792), AM encompasses various manufacturing andprototyping techniques known under a variety of names, includingfreeform fabrication, 3D printing, rapid prototyping/tooling, etc. AMtechniques are capable of fabricating complex components from a widevariety of materials. Generally, a freestanding object can be fabricatedfrom a computer aided design (CAD) model. A particular type of AMprocess uses electromagnetic radiation such as a laser beam, to solidifya photopolymer, creating a solid three-dimensional object.

FIG. 1 is schematic diagram showing a perspective view of an exemplaryconventional apparatus 100 for additive manufacturing. The apparatus 100uses selective laser activation (SLA) such as disclosed in U.S. Pat. No.5,256,340, assigned to 3D Systems, Inc. to form a part 130 as a seriesof layers. The apparatus 100 includes a vat 110 that holds a liquidphotopolymer 112, which may also be referred to as a resin. A buildplate 116 is oriented in an x-y plane and forms the base upon which thepart 130 is formed. An elevator 114 moves the build plate 116 along az-axis orthogonal to the x-y plane. A sweeper 118, spreads the liquidphotopolymer 112 across the build plate 116 and previously solidifiedlayers of the part 130.

A laser 120 provides a laser beam 126 that solidifies the liquidphotopolymer 112 according to a curing depth, which generallycorresponds to a layer thickness. Lenses 122 adjust properties of thelaser beam 126 such as beam width. A scanning mirror 124 reflects thelaser beam 126 at various angles to scan a pattern in a top layer of theliquid photopolymer 112. The apparatus 100 is under the control of acomputer 140 that directs the scanning mirror 124 as well as theelevator 118 and laser 120. The computer controls the apparatus 100 suchthat the laser 120 solidifies a scan pattern in the top layer of theliquid photopolymer 112. The elevator 114 then moves the build plate 116downward along the z-axis and the sweeper 118 spreads the liquidphotopolymer 112 to form a new top layer above the previously solidifiedphotopolymer. The process continues layer by layer until the part 130 isformed on the build plate 116.

Various additive manufacturing apparatuses operate on a slice-basedmodelling technique. For example, as described in U.S. Pat. No.5,184,307, a stereolithography system will typically form athree-dimensional part in accordance with a corresponding objectrepresentation, which representation may be formed in a CAD system orthe like. Before such a representation can be used, however, it must besliced into a plurality of layer representations. The stereolithographysystem will then, in the course of building up the object in a stepwiselayer-by-layer manner, selectively expose the untransformed layers ofmaterial in accordance with the layer representations to form the objectlayers, and thus, the object itself.

When exposing the untransformed layers of material, the scanning mirror124 traces a pattern in the layer. Generally, the stereolithographysystem will control the scanning mirror 124 to trace the outline of anyshapes in the layer, then fill the shape in with a series of hatchlines. The present inventors have discovered that various shapes such asthin walls do not necessarily form as solid parts. Instead, the shapemay include unsolidified liquid photopolymer within the part. Generally,stereolithography systems are designed for rapid prototyping toillustrate a design concept. Such uses do not require consistentmaterial properties or strict manufacturing tolerances. Accordingly,unsolidified liquid photopolymer may be acceptable for rapidprototyping. When stereolithography is used in commercial manufacturing,however, unsolidified liquid photopolymer within a part results in poormaterial properties (e.g., structural weakness) and the parts do notsatisfy manufacturing tolerances.

One solution to unsolidified liquid photopolymer is to increase thepower of the laser 120. The increased power, however, causes greatercure depths in the z-dimension in some portions of the part. This

The present inventors have further discovered that the unsolidifiedliquid photopolymer within the part is due to draw speeds. Generally,available additive manufacturing apparatuses set the draw speed tofinish parts as quickly as possible. Available additive manufacturingapparatuses do not allow user control of the draw speed.

In view of the above, it can be appreciated that there are problems,shortcomings or disadvantages associated with AM techniques, and that itwould be desirable if improved methods of forming thin walled structureswere available.

SUMMARY

The following presents a simplified summary of one or more aspects ofthe invention in order to provide a basic understanding of such aspects.This summary is not an extensive overview of all contemplated aspects,and is intended to neither identify key or critical elements of allaspects nor delineate the scope of any or all aspects. Its purpose is topresent some concepts of one or more aspects in a simplified form as aprelude to the more detailed description that is presented later.

In an aspect, the disclosure provides a method of manufacturing a partusing a stereolithography apparatus that cures a liquid photopolymerinto a solid polymer using a laser. The method includes scanning a firstportion of the photopolymer with the laser at a first draw speed,wherein the first portion of the photopolymer corresponds to a firstportion of the part that has a width less than a threshold width. Themethod also includes scanning a second portion of the photopolymer withthe laser at a second draw speed that is greater than the first drawspeed, wherein the second portion of the photopolymer corresponds to asecond portion of the part that has a width greater than the thresholdwidth.

In another aspect, the disclosure provides a stereolithography apparatusincluding a vat containing liquid photopolymer resin, a pulsed laserthat produces a laser pulses that irradiate the liquid photopolymerresin thereby solidifying the liquid photopolymer resin; and a scanningmirror that moves the laser beam across a surface of the liquidphotopolymer resin. The stereolithography apparatus also includes amemory storing executable instructions and a processor communicativelycoupled to the memory and configured to execute the instructions tocontrol the pulsed laser and scanning mirror. The instructions, whenexecuted, control the apparatus to scan a first portion of the liquidphotopolymer resin with the laser at a first draw speed, wherein thefirst portion of the photopolymer corresponds to a first portion of apart that has a width less than a threshold width and scan a secondportion of the photopolymer with the laser at a second draw speed thatis greater than the first draw speed, wherein the second portion of thephotopolymer corresponds to a second portion of the part that has awidth greater than the threshold width.

In another aspect, the disclosure provides a method of manufacturing apart using a stereolithography apparatus that cures a liquidphotopolymer into a solid polymer using a laser. The method includesscanning the liquid photopolymer using a pulsed laser having arepetition rate of at least 67,000 pulses per second at a draw speedless than 50 inches per second.

These and other aspects of the invention will become more fullyunderstood upon a review of the detailed description, which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic diagram showing an example of a conventionalapparatus for additive manufacturing.

FIG. 2 illustrates a schematic diagram showing a scan pattern for a thinwalled portion of a part.

FIG. 3 illustrates a schematic diagram showing the locations of laserpulses according to the scan pattern of FIG. 2 with a draw speed ofapproximately 100 inches per second.

FIG. 4 illustrates a schematic diagram showing the locations of laserpulses according to the scan pattern of FIG. 2 with a draw speed ofapproximately 40 inches per second.

FIG. 5 illustrates a horizontal cross-sectional view of an example layerof a part including several portions

FIG. 6 illustrates a vertical cross section of a part including multipleportions.

FIG. 7 is a photograph of two parts manufactured with a draw speed ofapproximately 120 inches per second

FIG. 8 is a photograph of two parts manufactured with a draw speed ofapproximately 40 inches per second.

FIG. 9 is a photograph of an example part having a plurality of hollowcylinders oriented horizontally that was manufactured with a draw speedof approximately 120 inches per second.

FIG. 10 is a photograph of an example part having a plurality of hollowcylinders oriented horizontally that was manufactured using a draw speedof approximately 40 inches per second.

FIG. 11 is a conceptual diagram showing components of an exemplaryadditive manufacturing system according to an aspect of the disclosure.

FIG. 12 is a flowchart illustrating an example method of manufacturing apart.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of various configurations and isnot intended to represent the only configurations in which the conceptsdescribed herein may be practiced. The detailed description includesspecific details for the purpose of providing a thorough understandingof various concepts. However, it will be apparent to those skilled inthe art that these concepts may be practiced without these specificdetails. In some instances, well known components are shown in blockdiagram form in order to avoid obscuring such concepts.

FIG. 2 illustrates a schematic diagram showing a scan pattern 200 for ahorizontal cross section of a part. The horizontal cross section lies inan x-y plane along an x-axis 202 and a y-axis 204. It should beappreciated that the part also extends along a z-axis orthogonal to thex-y plane. The part is formed along the z-axis by layering scan patternsin the x-y plane. Generally, the scan pattern is derived from a layerrepresentation of an object. The apparatus 100 analyzes the layerrepresentation to find the edges of shapes (e.g., polygons). Theapparatus 100 then plots a scan pattern that first traces the edges ofthe shapes. The apparatus 100 then adds hatch lines to the scan patternto fill the internal space between the edges with a series ofoverlapping lines.

The scan pattern 200 is for a part including a thin walled portion 210.The part may include other portions that are not shown. A thin wallportion is generally less than 0.030 inch thick. In an aspect, a thinwall portion may be 0.020 inch thick, 0.010 inch thick, or thinner. Thescan pattern 200 includes a first edge line 212 extending the length ofthe thin walled portion 210 and a second edge line 214 extending thelength of the thin walled portion 210. The apparatus 100 may scan thefirst edge line 212 and the second edge line 214 in opposite directions.The scan pattern 200 also includes hatch lines 220. The hatch lines 220are generally perpendicular to the first edge line 212 and the secondedge line 214. In an aspect, the hatch lines 220 may be a single pathincluding hatch segments 222, 224, 226, 228 between the first edge line212 and second edge line 214 as well as segments that extend along thefirst edge line 212 and second edge line 214 for the width between thehatch segments. In another aspect, the hatch lines 220 are a series ofunconnected hatch segments 222, 224, 226, 228.

A distance between the hatch segments 222, 224, 226, 228 is based on abeam width of the laser 120 and an overlap percentage. The distancebetween the hatch segments 222, 224, 226, 228 is set so that the scannedarea overlaps by the overlap percentage. In an aspect, the laser 120 isa pulsed laser that radiates the liquid photopolymer 112 in a series ofpulses at a repetition rate. Various lasers may be used that producepulses at desired wavelengths with desired repetition rates. Forexample, available SLA systems have a repetition rate between 25,000 and200,000 cycles per second. In an aspect, the repetition rate is at least67,000 cycles per second.

The apparatus 100 traces the scan pattern 200 at a draw speed. Thepulses of the laser 120 irradiate a series of circles in the liquidphotopolymer 112 as the scanning mirror 124 traces the scan pattern. Inan aspect, for each circle, the liquid photopolymer closest to thecenter is cured, but the photopolymer near the edges of the circle donot receive the same intensity of radiation and do not fully cure, or donot cure to the same depth. Depending on the draw speed, the circlesirradiated in consecutive pulses will overlap. The overlapping portionsare exposed to a greater amount of radiation and therefore cure to agreater depth.

FIG. 3 illustrates an example part 300 including a thin walled portionformed using conventional techniques and a draw speed of approximately100 inches per second. The part 300 is formed using the scan pattern 200including the first edge line 212, the second edge line 214, and thehatch segments 222, 224, 226, 228. As illustrated, the width 310 of thepart 300 is wider than the length of the hatch segments 222, 224, 226,228 by a line width compensation 312, which is approximately half of thecured line width. For example, the line width compensation 312 may beapproximately 1 mil or 0.001 inch.

The part 300 also includes gaps. In a finished part, the gaps may befiled with unsolidified liquid photopolymer 112, or the liquidphotopolymer 112 may leak out of the gaps, leaving a porous structure.The gaps may be the result of a shutter operation of the apparatus 100.When the scanning mirror 124 moves the beam over the previously scannedportions of the first edge line 212 and the second edge line 214, thelenses 122 close a shutter to prevent overexposure of the alreadysolidified photopolymer. When the scan pattern 200 includes quickdirection changes for the hatch lines of a thin walled structure, theshutter keeps the laser 120 from forming a portion of the hatch lines.For example, the lenses 122 may close the shutter a pre-edge distance314 before reaching an edge line and open the shutter a post-edgedistance 316 after moving past the edge line. In an aspect, the pre-edgedistance 314 may be based on a time of approximately 10 μs, and thepost-edge distance 316 may be based on a time of approximately 35 μs.For a part with a thin-walled portion having a width of 0.01 inch, theline width compensation 312 results in a scanning length 318 of hatchsegments 222, 224, 226, 228 of 0.008 inch. When the conventional drawspeed determination is used, the draw speed is, for example,approximately 120 inches per second. The pre-edge distance 314 isapproximately 0.0012 inches and the post-edge distance 316 isapproximately 0.0042 inches. These distances leave substantial gaps inthe thin walled structure that are not solidified.

In an aspect, gaps in thin walled structures are prevented by using adraw speed less than 50 inches per second. The intensity of the laser120 is greater toward the center than the edges. Depending on the liquidphotopolymer 112, the laser 120 may not solidify the entire area of thebeam with a single pulse. Accordingly, the laser 120 produces a curedline width that is less than the beam width. The cured line width alsodepends on the overlap percentage because the chord formed between theintersecting points of the overlapping circles may define a curedportion that has been exposed to two consecutive pulses.

FIG. 4 illustrates an example part 400 including a thin walled portionformed using a speed of approximately 40 inches per second. The part 400is formed using the scan pattern 200 including the first edge line 212,the second edge line 214, and the hatch segments 222, 224, 226, 228. Asillustrated in FIG. 4, the reduced draw speed results in greater overlapof the circles irradiated by the laser pulses. Moreover, the reduceddraw speed decreases the effect of the shutter. Instead of the pre-edgetime of approximately 10 μs producing a pre-edge distance ofapproximately 0.00012 inches, the pre-edge distance 414 is approximately0.0004 inches. Similarly, the post-edge distance 416 may be reduced toapproximately 0.0014 inches. These distances may be less than the curedline width and may prevent the formation of any gaps in the thin walledstructures. In an aspect, the line width compensation 412 may also bebased on the cured line width.

FIG. 5 illustrates a horizontal cross-sectional view of an example layer500 of a part including several portions. The layer 500 is oriented inthe x-y plane along the x-axis 202 and the y-axis 204. Generally, anadditive manufacturing apparatus 100 slices a three-dimensional model(e.g., a CAD model) of a part to obtain a layer representation. Theapparatus 100 then divides the layer representation into shapes (e.g.,polygons). In an aspect, the apparatus 100 determines a draw speed foreach shape, or a portion thereof, based on a width of the shape. Thewidth is generally the smallest dimension of the shape in the x-y plane.In an aspect, the width may also be measured in the direction of hatchlines used to fill the interior of the shape. The width is compared to athreshold width 520 to determine whether to use a draw speed based onthe cured line width. In an aspect, the threshold width may be a widthless than 0.3 inches, preferably less than 0.2 inches, and as small as0.005 inches. The threshold may also be based on the cured line width,for example, the threshold may be 20 times the cured line width.

Portion 502 is a relatively wide rectangle. The dimensions of theportion 502 exceed the threshold width 520 in both the x and ydimensions. Accordingly, the apparatus 100 scans the portion 502 using ahigher draw speed, which may be based on a beam width. The higher drawspeed is, for example, greater than 100 inches per second.

Portion 504 has a width in the x dimension that is less than thethreshold width 520. Accordingly, the apparatus 100 scans the portion504 using a lower draw speed, which may be based on the cured linewidth. The lower draw speed is, for example, less than 50 inches persecond.

A shape may also include multiple portions. For example, the shape 530includes portions 532, 534, and 536. Portion 532 is a relatively widerectangle having dimensions that exceed the threshold width 520 in boththe x and y dimensions. Accordingly, the apparatus 100 scans the portion532 using the higher draw speed. The portion 534 has a y dimension lessthan the threshold width 520. Accordingly, the width of the portion 534is considered along the y dimension and the apparatus 100 scans theportion 534 using the lower draw speed. In an aspect, if the hatch linesare oriented in the x dimension, the width of portion 524 is consideredto exceed the threshold width 520 and the portion 534 is scanned usingthe higher draw speed. Portion 536 has a width in the x dimension thatis less than the threshold width 520. Accordingly, the portion 536 isscanned using the lower draw speed.

FIG. 6 illustrates a vertical cross section of a part 600 includingmultiple portions. A base portion 602 has a width in the x-dimensionthat exceeds the threshold width 520. As the part 600 reaches the height604, some portions built on top of the base portion 602 have a widthless than the threshold width 620. For example, portions 610, 612, 614,618 and 620 have a width less than the threshold width 620. Accordingly,the portions 610, 612, 614, 618 and 620 are scanned using the lower drawspeed. In contrast, the portion 616 has a width exceeding the thresholdwidth 620 and is scanned with the higher draw speed. A portion 622 has avariable width. The draw speed for portion 622 is selected for eachlayer. For example, the base of portion 622 has a width greater than thethreshold width 620 and is scanned with the greater draw speed. When theportion 622 reaches the height 624, the width becomes less than thethreshold width 620. Accordingly, a portion 626 above the height 624 isscanned with the lower draw speed.

FIG. 7 is a photograph of two parts manufactured with a draw speed ofapproximately 120 inches per second. In each part, a top portion is avertical cylinder and a bottom portion is a rectangular vertical wall.In the part 710, both portions have a width of 0.010 inch. In the part720, both portions have a width of 0.020 inch. The light colored areasare places where the liquid photopolymer did not fully cure. The problemof uncured liquid photopolymer is more pronounced in part 710, but alsoa problem in part 720.

FIG. 8 is a photograph of two parts manufactured with a draw speed ofapproximately 40 inches per second. The part 810 corresponds to the part710, i.e., they were based on the same CAD model and were intended tohave the same dimensions. Similarly, the part 820 corresponds to thepart 720. In FIG. 8, the walls have significantly less uncuredphotopolymer.

Using a reduced draw speed based on the cured line width also affectsthin walled structures and other fine features oriented transverse tothe x-y plane. FIG. 9 is a photograph of an example part 900 having aplurality of hollow cylinders oriented horizontally. The part 900 wasmanufactured with a draw speed of approximately 120 inches per second.The bottom edges of the cylinders are not round because portions of thecylinder cure to a deeper depth than others. For example, when formingthe edge lines in a layer of the cylinders, the pulses are evenlyspaced. However, the hatch lines oriented transverse to the axis of thecylinders include gaps as in FIG. 3. Accordingly, the sides of thecylinders cure to a greater depth than the bottom of the cylinder,producing a shape that is out of round.

FIG. 10 illustrates an example of a part 1000 having a plurality ofhollow cylinders oriented horizontally that is manufactured using a drawspeed of approximately 40 inches per second. The lower draw speedresults in a more consistent cure depth and a more rounded shape.

Although the present disclosure has been described with respect to anSLA AM process, it should be appreciated that other AM processes such asdirect metal laser sintering (DMLS) and direct metal laser melting(DMLM) use similar scanning techniques. Selective laser sintering,direct laser sintering, selective laser melting, and direct lasermelting are common industry terms used to refer to producingthree-dimensional (3D) objects by using a laser beam to sinter or melt afine powder. For example, U.S. Pat. No. 4,863,538 and U.S. Pat. No.5,460,758 describe conventional laser sintering techniques.

As another example, the techniques described herein can be applied todigital light projection (DLP). In one aspect, DLP may be similar to SLAin that light is projected downward onto a liquid surface. In anotheraspect, DLP differs from the above discussed powder bed and SLAprocesses in that the light curing of the polymer occurs through awindow at the bottom of a resin tank that projects light upon a buildplatform that is raised as the process is conducted. Further, thepolymerization occurs between the underlying window and the last curedlayer of the object being built. One suitable DLP process is disclosedin U.S. Pat. No. 9,079,357 assigned to Ivoclar Vivadent AG and TechnisheUniversitat Wien, as well as WO 2010/045950 A1 and U.S. PublicationNumber 2011/0310370, each of which are hereby incorporated by reference.

FIG. 11 is a conceptual diagram showing components of an exemplaryadditive manufacturing system 1100 according to an aspect of thedisclosure. In an aspect, the additive manufacturing system 1100 may bean SLA system that includes various components of the additivemanufacturing apparatus 100 (FIG. 1) such as the vat 110, liquidphotopolymer 112, elevator 114, build plate 116, recoater 118, laser120, lenses 122, and scanning mirror 124. As mentioned above, thedisclosed techniques may be used with other layer based additivemanufacturing apparatuses and similar components may perform similarfunctions. For example, the additive manufacturing system 1100 mayinclude a container that stores a raw material such as the vat 110, atank having a translucent bottom portion in an DLP system, or a powderbed in a DLMS or powder ceramic system. The additive manufacturingsystem 1100 also includes a radiation source that solidifies the rawmaterial when applied to the raw material. For example, the laser 120 isa radiation source and other radiation sources include an energy beam,and a light source (including ultra-violet light). The additivemanufacturing system 1100 also includes a scanner that applies theradiation source to portions of the raw material within a current layerto form a portion of an object. The scanner may include the scanningmirror 124, a galvo scanner, or a modulator with which the intensity ofa light source can be adjusted position-selectively under the control ofa control unit. The additive manufacturing system 1100 also includes anelevator that moves the raw material or the object to change the currentlayer. The elevator may include the elevator 114, an adjustable buildplate, or an elevator that moves the radiation source.

The additive manufacturing system 1100 also includes a computer 1110.The computer 1110 may be a separate computer or may be integrated withthe above components of the additive manufacturing system 1100. Thecomputer 1110 may include a digital processor communicatively coupled toa computer-readable medium such as a random access memory and/or harddrive. The computer-readable medium may store computer executableinstructions that are executed by the processor to control the additivemanufacturing system 1100. In an aspect, the computer executableinstructions are firmware for controlling the additive manufacturingsystem 1100. In another aspect, the computer executable instructionsinclude a CAD program and/or a standalone program for performing thetechniques disclosed herein.

The computer 1110 includes draw speed component 1120. In an aspect, thedraw speed component 1120 is a processor configured execute computerexecutable instructions stored on a computer-readable storage medium.The draw speed component 1120 includes a slicing component 1122 that isconfigured to generate layer representations of an object based on a 3Dmodel of the object according to a slicing algorithm. For example, theslicing algorithm may average the positions of the object in a top sliceand a bottom slice to determine the boundaries of the layerrepresentation between the slices. The slicing component 1222 maydetermine a width of the object or a portion thereof based on a width ofa slice. The draw speed component 1120 also includes a selectioncomponent 1124. The threshold component 1224 may be configured todetermine whether a portion of an object has a width less than thethreshold width. The draw speed component 1120 also includes a selectioncomponent 1126. The selection component 1126 is configured to select adraw speed based on whether the width is less than the threshold. Forexample, the selection component 1126 selects a first, relatively low,draw speed when the width is less than the threshold and selects asecond, relatively high, draw speed when the width is greater than thethreshold. In an aspect, the selection component may select a draw speedbased on other factors such as repetition rate, beam width, cured linewidth, overlap percentage. The cured line width may be based on the rawmaterial such as the liquid photopolymer. In an aspect, the selectioncomponent 1226 may select a draw speed corresponding to a current liquidphotopolymer in use.

FIG. 12 is a flowchart illustrating an example method 1200 ofmanufacturing a part. The method 1200 is performed by a speciallyprogrammed computer (e.g., computer 1110) that controls an additivemanufacturing system 1100. In an aspect, the specially programmedcomputer is part of the additive manufacturing system 1100 and includesfirmware for controlling the additive manufacturing system 1100. In anaspect, the specially programmed computer also includes a CAD programthat processes a three-dimensional model of a part. The speciallyprogrammed computer may further include an extension to the CAD programthat performs the method 1200 or a separate program that controls thecomputer to perform the method 1200. The computer program may be storedon a non-transitory computer-readable storage medium as computerexecutable code for controlling the computer 1110 and/or the system1100. In an aspect, the computer 1110 is communicatively coupled to anAM apparatus such as the system 1100. The system 1100 operates based ona three dimensional model of the part (e.g., part 130). The model of thepart is oriented according to an x-y build plane corresponding to anorientation of a layer of the part and a z-axis orthogonal to the x-ybuild plane that defines an order of each layer of the part.

In block 1210, the method 1200 optionally includes determining a curedline width for an additive manufacturing apparatus and a resin. Forexample, the selection component 1226 determines the cured line widthfor the additive manufacturing system 1100 and a resin. For example, theresin is the liquid photopolymer 112 currently in the vat 110. In anaspect, the computer 1110 determines the cured line width according to atable of stored values for a combination of active parameters. Inanother aspect, the additive manufacturing system 1100 measures curedline width. For example, the additive manufacturing system 1100 maymeasure a cured line width formed when scanning an edge line 212 or 214.In another aspect, an operator enters the cured line width for thesystem 1100 and the resin.

In block 1220, the method 1200 optionally includes determining a firstdraw speed for the additive manufacturing apparatus. In an aspect, thecomputer 1110 determines the first draw speed. The first draw speed maybe based on other parameters of the apparatus 100 such as, for example,a repetition rate of laser 120, a desired overlap percentage, or a beamwidth. In an aspect, the cured line width may be dependent on one ormore of the repetition rate of laser 120, the desired overlappercentage, or the beam width. In another aspect, a first draw speedcorresponding to various liquid photopolymers may be stored in a look uptable. The selection component 1226 may determine a current liquidphotopolymer and select the corresponding first draw speed.

In block 1230, the method 1200 includes determining whether a portion ofthe part has a width less than a threshold width. The thresholdcomponent 1224 compares the width of the part to the threshold width. Ifthe width of the portion is less than the threshold width, the method1200 proceeds to block 1240. If the width of the portion is not lessthan the threshold width, the method 1200 proceeds to block 1260.

In block 1240, the method 1200 optionally includes setting a laser powerof the additive manufacturing system 1100 based on the first draw speed.In an aspect, for example, the computer 1110 sets the power of the laser120 based on the first draw speed. The first draw speed determines anumber of pulses in an area and the overlap of the pulses. The computer1110 sets the power of the laser 120 control a cured depth. For example,the computer 1110 sets the cure depth equal to a build layer thickness.

In block 1260, the method 1200 includes scanning at least a firstportion of the part using the first draw speed. In an aspect, forexample, the system 1100 scans the at least first portion of the part(as determined by a CAD model) using the scanning mirror 124 to move thebeam of the laser 120 at the first draw speed. In an aspect, the firstportion of the part is a thin wall having a width less than a thresholdwidth. The thin wall may, for example, have a width less than 0.3inches, preferably less than 0.2 inches. The width of the thin wall isless than 20 times the cured line width. In an aspect, the first portionincludes an interior of a shape. For example, referring to FIG. 2, thehatch lines 220 are scanned using the first draw speed. In anotheraspect, the entire thin walled portion 210 is scanned using the firstdraw speed.

In block 1260, the method 1200 optionally includes setting the laserpower of the additive manufacturing apparatus based on the second drawspeed. Similar to block 1240, for example, the computer 140 sets thepower of the laser 120 based on the second draw speed before scanningusing the second draw speed to control a cured depth.

In block 1270, the method 700 includes scanning a second portion of thepart using the second draw speed. In an aspect, for example, the system1100 scans the second portion of the part (as determined by a CAD model)using the scanning mirror 124 to move the beam of the laser 120 at thesecond draw speed. In an aspect, the second portion of the part has awidth greater than the threshold width. For example, the second portionof the part has a width greater than 0.3 inches. In an aspect, anyportion of the part may be classified by the computer 1110 as a thinwalled portion having a width less than the threshold width or a thickerportion having a width greater than the threshold width. The system 1100scans the thin walled portions using the first draw speed and scans thethicker portions using the second draw speed. In another aspect, thesecond portion may include an external surface of a shape. The system1100 may scan the external surfaces or edges of the shape with thesecond draw speed even if the shape is a thin portion because theexternal edges are longer than the width and in a different direction.

This written description uses examples to disclose the invention,including the preferred embodiments, and also to enable any personskilled in the art to practice the invention, including making and usingany devices or systems and performing any incorporated methods. Thepatentable scope of the invention is defined by the claims, and mayinclude other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal language of the claims.Aspects from the various embodiments described, as well as other knownequivalents for each such aspect, can be mixed and matched by one ofordinary skill in the art to construct additional embodiments andtechniques in accordance with principles of this application.

1. A method of manufacturing a part using an additive manufacturingapparatus that solidifies a raw material using a laser, the methodcomprising: scanning a first portion of the raw material with the laserat a first draw speed, wherein the first portion of the raw materialcorresponds to a first portion of the part that has a width less than athreshold width; and scanning a second portion of the raw material withthe laser at a second draw speed that is greater than the first drawspeed, wherein the second portion of the raw material corresponds to asecond portion of the part that has a width greater than the thresholdwidth.
 2. The method of claim 1, wherein the threshold width is between0.005 inches and 0.030 inches.
 3. The method of claim 1, wherein theadditive manufacturing apparatus is a stereolithography apparatus andthe laser is a pulsed laser.
 4. The method of claim 3, wherein the firstdraw speed is less than 50 inches per second and the second draw speedis greater than 100 inches per second.
 5. The method of claim 4, whereinthe first draw speed is less than 40 inches per second.
 6. The method ofclaim 4, wherein the second draw speed is greater than 120 inches persecond.
 7. The method of claim 3, wherein the pulsed laser has arepetition rate between 25,000 and 200,000 cycles per second.
 8. Themethod of claim 1, further comprising: determining, by thestereolithography apparatus, for each portion of the part, whether theportion has a width less than the threshold width; and selecting, by thestereolithography apparatus, the first draw speed or the second drawspeed for the respective part based on the determination.
 9. The methodof claim 1, wherein the first portion of the part and the second portionof the part are located at least partially in a single horizontal layerof the part.
 10. The method of claim 1, wherein the first portion of thepart and the second portion of the part are located in different layersof the part, wherein the first draw speed is used for layers includingthe first portion of the part, and the second draw speed is used forlayers including the second portion of the part.
 11. The method of claim1, further comprising setting a laser power for the first portion basedon the first draw speed.
 12. A stereolithography apparatus comprising: avat containing liquid photopolymer resin; a pulsed laser that produces alaser beam that irradiates the liquid photopolymer resin therebysolidifying the liquid photopolymer resin; a scanning mirror that movesthe laser beam across a surface of the liquid photopolymer resin; amemory storing executable instructions; a processor communicativelycoupled to the memory and configured to execute the instructions tocontrol the laser and scanning mirror to: scan a first portion of theliquid photopolymer resin with the laser at a first draw speed, whereinthe first portion of the photopolymer corresponds to a first portion ofa part that has a width less than a threshold width; and scan a secondportion of the photopolymer with the laser at a second draw speed thatis greater than the first draw speed, wherein the second portion of thephotopolymer corresponds to a second portion of the part that has awidth greater than the threshold width.
 13. A method of manufacturing apart using a stereolithography apparatus that cures a liquidphotopolymer into a solid polymer using a laser, the method comprising:scanning the liquid photopolymer using a pulsed laser having arepetition rate of at least 67,000 pulses per second at a draw speedless than 50 inches per second.
 14. The method of claim 13, wherein thedraw speed is less than 40 inches per second.